MTU 12-16V2000 M72 Operating Instructions

Operating InstructionsDiesel engine12 V 2000 M7216V 2000 M72

M015650/03E

Printed in Germany 2011 Copyright MTU Friedrichshafen GmbHThis Publication is protected by copyright and may not be used in any way whether in whole or in part without the priorwritten permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on electronic systems including data bases and online services.This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damageduring operation.Subject to alterations and amendments.

Commissioning NoteImportantPlease complete and return the Commissioning Note card below to MTU Friedrichshafen GmbH.The Commissioning Note information serves as a basis for the contractually agreed logistic support (warranty, spare parts, etc.).

Table of Contents1 Safety1.1 General conditions 71.2 Personnel and organizational requirements 81.3 Transport 91.4 Safety regulations for startup and operation 101.5 Safety precautions when working on the

engine 111.6 Auxiliary materials, fire prevention and

environmental protection 131.7 Conventions for safety instructions in the

text 16

2 General Information2.1 Engine side and cylinder designations 172.2 Product description 182.3 Engine layout 242.4 Sensors, actuators and injectors

Overview 26

3 Technical Data3.1 12V 2000 M72 engine data: Engine-

mounted heat exchanger, EPA stage 2 313.2 12 V 2000 M72 engine data: remote heat

exchanger, EPA stage 2 343.3 16V 2000 M72 engine data: Engine-

mounted heat exchanger, EPA stage 2 373.4 16V 2000 M72 engine data: Separate heat

exchanger, EPA stage 2 403.5 Firing order 433.6 Engine Main dimensions 44

4 Operation4.1 Engine Putting the engine into operation

(out of service > 3 months) 454.2 Putting the engine into operation after

scheduled out-of-service period 464.3 Tasks after extended out-of-service periods

(>3 weeks) 474.4 Checks prior to start-up 484.5 Fuel treatment system Start-up 494.6 Operational checks 514.7 Fuel treatment system Switching on 524.8 Starting the engine 53

4.9 Stopping the engine 544.10 Emergency stop 554.11 After stopping the engine 564.12 Fuel treatment system Shutdown 574.13 Plant Cleaning 58

5 Maintenance5.1 Maintenance task reference table [QL1] 59

6 Troubleshooting6.1 Fuel treatment system Troubleshooting 606.2 Troubleshooting 61

7 Task Description7.1 SOLAS 64

7.1.1 SOLAS shielding as per MTN 5233 Installation 64

7.1.2 SOLAS shielding - Installation 657.1.3 Installation locations for SOLAS shielding 66

7.2 Engine 727.2.1 Engine Barring manually 727.2.2 Engine Barring with starting system 73

7.3 Cylinder Liner 747.3.1 Cylinder liner Endoscopic examination 747.3.2 Instructions and comments on endoscopic

and visual examination of cylinder liners 767.4 Crankcase Breather 78

7.4.1 Crankcase breather Cleaning oil pre-separator element 78

7.4.2 Crankcase breather Oil separatorreplacement, diaphragm check andreplacement 79

7.5 Valve Drive 817.5.1 Valve clearance Check and adjustment 817.5.2 Cylinder-head cover Removal and

installation 847.6 Injection Valve / Injector 85

7.6.1 Injector Replacement 857.6.2 Injector Removal and installation 86

7.7 Fuel System 887.7.1 Fuel system Venting 88

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7.8 Fuel Filter 897.8.1 Fuel filter Replacement 897.8.2 Fuel prefilter Differential pressure check and

adjustment of gauge 917.8.3 Fuel prefilter Draining 927.8.4 Fuel prefilter Flushing 937.8.5 Fuel prefilter Filter element replacement 95

7.9 Charge-Air Cooling 977.9.1 Intercooler Checking condensate drain line

for coolant discharge and obstruction 977.10 Air Filter 98

7.10.1 Air filter Replacement 987.10.2 Air filter Removal and installation 99

7.11 Air Intake 1007.11.1 Service indicator - Signal ring position check 100

7.12 Starting Equipment 1017.12.1 Starter Condition check 101

7.13 Lube Oil System, Lube Oil Circuit 1027.13.1 Engine oil Level check 1027.13.2 Engine oil Change 103

7.14 Oil Filtration / Cooling 1047.14.1 Engine oil filter Replacement 1047.14.2 Centrifugal oil filter Cleaning and filter-

sleeve replacement 1067.15 Coolant Circuit, General, High-

Temperature Circuit 1097.15.1 Drain and venting points 1097.15.2 Engine coolant Level check 1157.15.3 Engine coolant Change 1167.15.4 Engine coolant Draining 1177.15.5 Engine coolant Filling 1187.15.6 HT coolant pump Relief bore check 1197.15.7 Engine coolant Sample extraction and

analysis 1207.15.8 Coolant filter Replacement 121

7.16 Raw Water Pump with Connections 1227.16.1 Raw water pump Relief bore check 122

7.17 Belt Drive 1237.17.1 Drive belt Condition check 123

7.18 Battery-Charging Generator 1247.18.1 Battery-charging generator drive Drive belt

replacement 1247.19 Fuel Treatment System 125

7.19.1 Water drain valve Check 1257.19.2 Differential pressure gauge Check 1267.19.3 Water level probe (3-in-1 rod electrode)

Check 1277.19.4 Pump capacity Check 1287.19.5 Coalescer filter element Replacement 129

7.20 Wiring (General) for Engine/Gearbox/Unit 1317.20.1 Engine wiring Check 131

7.21 Accessories for (Electronic) EngineGovernor / Control System 132

7.21.1 Engine governor and connectors Cleaning 1327.21.2 Engine governor Checking plug-in

connections 1337.21.3 EMU Checking plug-in connections 1347.21.4 Engine governor Carry out self-test 1357.21.5 EMU and connectors Cleaning 1367.21.6 ECU 7 engine governor Removal and

installation 1377.21.7 Engine monitoring unit Removal and

installation 138

8 Appendix A8.1 Abbreviations 1398.2 MTU contacts/service partners 142

9 Appendix B9.1 Special Tools 1439.2 Index 146

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1 Safety1.1 General conditions

GeneralIn addition to the instructions in this publication, the applicable country-specific legislation and other compulsory regulations regarding accident prevention and environmental protection must be observed. Thisstate-of-the-art engine has been designed to meet all applicable laws and regulations. The engine maynevertheless present a risk of injury or damage in the following cases: Incorrect use Operation, maintenance and repair by unqualified personnel Modifications or conversions Noncompliance with the Safety InstructionsCorrect useThe engine is intended solely for use in accordance with contractual agreements and the purpose envisaged for it on delivery. Any other use is considered improper use. The engine manufacturer accepts noliability whatsoever for resultant damage or injury in such case. The responsibility is borne by the useralone.Correct use also includes observation of and compliance with the operating instructions and maintenance and repair specifications.Modifications or conversionsUnauthorized modifications to the engine represent a safety risk.MTU will accept no liability or warranty claims for any damage caused by unauthorized modifications orconversions.Spare partsOnly genuine MTU spare parts must be used to replace components or assemblies. MTU accepts noliability whatsoever for damage or injury resulting from the use of other spare parts and the warranty shallbe voided in such case.Reworking componentsRepair or engine overhaul must be carried out in workshops authorized by MTU.

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1.2 Personnel and organizational requirementsPersonnel requirementsWork on the engine must only be carried out by appropriately qualified and instructed personnel.Observe the minimum legal age.Responsibilities of the operating, maintenance and repair personnel must be specified by the operatingcompany.Organizational measuresThis publication must be issued to all personnel involved in operation, maintenance, repair or transportation.Keep it handy in the vicinity of the engine such that it is accessible to operating, maintenance, repair andtransport personnel at all times.Use the manual as a basis for instructing personnel on engine operation and repair. In particular, personnel must have read and understood the safety-relevant instructions.This is especially important for personnel who work on the engine only on an occasional basis. Thesepersons shall receive repeated instruction.Use the Spare Parts Catalog to identify spare parts during maintenance and repair work.Working clothes and protective equipmentWear proper protective clothing for all work.Depending on the kind of work, use the necessary personal protective equipment.

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1.3 TransportTransportOnly use the lifting eyes provided to lift the engine.Only use transport and lifting devices approved by MTU.Take the engine's center of gravity into account.The engine must only be transported in installation position, max. permissible diagonal pull 10.If the engine is supplied with special aluminum foil packing, lift the engine at the lifting eyes of the bearing pedestal or use a means of transportation which is appropriate for the given weight (forklift truck).Install the crankshaft locking device and the locking screws for the engine mounts prior to engine transportation.Secure the engine against tilting during transport. In particular when going down inclines or ramps, theengine must be secured against moving and tilting.Setting the engine down after transportOnly set down engine on a firm, level surface.Make sure that the consistency and load-bearing capacity of the ground or support surface is adequate.Never set an engine down on the oil pan unless expressively authorized to do so by MTU on a case-to-case basis.

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1.4 Safety regulations for startup and operationSafety requirements for initial operationPrior to initial operation of the unit, install the assembly or unit according to the specifications and checkthe installation according to the MTU specifications.Before putting the device or plant into operation, always ensure: that all maintenance and repair work is completed, that all loose parts have been removed from rotating machine components, that nobody is in the danger area of moving machine parts.Immediately after putting the device or plant into operation, make sure that all control and display instruments as well as the signaling and alarm systems work properly.Safety requirements for operatorsThe procedures for cases of emergency must be practiced regularly.The operator must be familiar with the control and display elements.The operator must be familiar with the consequences of any operations performed.During operation, the display instruments and monitoring units must be permanently observed with regard to present operating status, violation of limit values and warning or alarm messages.The following steps must be taken if a malfunction of the system is recognized or reported by the system: inform supervisor(s) in charge, analyze the message, if required, carry out emergency operations e.g. emergency engine stop.Engine operationThe following conditions must be fulfilled before starting the engine: Wear ear protection. Ensure that the engine room is well ventilated. Do not inhale engine exhaust gases. Ensure that the exhaust system is free of leaks and that the gases are discharged to atmosphere. Mop up any leaked or spilt fluids and lubricants immediately or soak up with a suitable binding agent. Protect battery terminals, battery-charger terminals and cables against accidental contact. When the engine is running, never release coolant, oil, fuel, compressed-air or hydraulic lines.Operation of electrical equipmentWhen electrical equipment is in operation, certain components of these appliances are electrically live.Observe the safety instructions for these devices.

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1.5 Safety precautions when working on the engineSafety requirements for maintenance and repair work Maintenance and repair work may only be carried out by authorized, qualified personnel. Allow the engine to cool down before commencing maintenance work (oil vapors present a risk of ex

plosion). Before starting work, relieve pressure in systems and compressed-air lines which are to be opened. Take special care when removing ventilation or plug screws from engine. Cover the screw or plug with

a rag to prevent fluids escaping under pressure. Take special care when draining hot fluids risk of burning. When changing the engine oil or working on the fuel system, ensure that the engine room is ade

quately ventilated. Prior to all work, allow the engine / genset to cool down. Observe maintenance and repair instructions. Never perform care or maintenance work with the engine running unless expressly instructed to do so. Lock-out/tag-out the engine to preclude undesired starting. With electric starter, disconnect the battery. Close the main valve on the compressed-air system and vent the compressed-air line when air start

ers are fitted. Disconnect the control device from the assembly or plant. Only use adequate, calibrated tools.During assembly and disassembly, observe the specified tighten

ing torques. Carry out work only on assemblies or plants that are secured as specified. Do not use lines as climbing aids. Keep fuel injection lines and connections clean. Always fit caps/covers to close off any openings exposed by removing or opening lines. Take care to avoid damaging fuel lines in the course of care and maintenance work. Ensure that all mounts and dampers are correctly installed. Ensure that all fuel injection and pressurized oil lines are installed with enough space to prevent con

tact with other components. Do not place fuel or oil lines near hot components. Do not touch elastomeric seals (e.g. Viton sealing rings) if they have carbonized or resinous appear

ance. Note cooling period for components which are heated for installation or removal Risk of burning! When working high on the engine, always use suitable ladders and work platforms. Make sure compo

nents are placed on stable surfaces. Observe special cleanness during maintenance and repair work on the assembly or plant. After com

pletion of maintenance and repair work, make sure that no loose objects are in/on the assembly orplant.

Ensure that all personnel is clear of danger zones before turning the engine. Check that all guardshave been reinstalled and that all tools and loose parts have been removed after working on the engine.

If starters with beryllium copper pinions are installed, the following also applies:To avoid health risks with the pinion containing beryllium, breathing protection of filter class P2 mustbe worn during maintenance work. Do not blow out the interior of the flywheel housing and the starterwith compressed air. The interior of the flywheel housing must be additionally cleaned with a dust-removal machine of class H.

Welding workNever carry out welding work on the assembly or engine plant or mounted units. Cover the engine whenwelding in its vicinity.Do not use the assembly or plant as a ground terminal.Never place the welding cable across or near wiring harnesses of MTU plants. The welding current mayotherwise induce an interference voltage in the wiring harnesses which could damage the electrical system.

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If welding has to be carried out on components (e.g. exhaust manifold), these components must first beremoved from the engine.Hydraulic installation and removalCheck the tools and devices to be used for perfect operation and safe condition. Only use the specifieddevices for force-fitting/removing parts.Observe the maximum press-on pressure for the device for force-fitting/removing parts.Do not attempt to bend or exert force on H.P. lines.Observe the following before starting the pressing procedure: Bleed air from jigs and fixtures for force-fitting/removing parts, pumps and piping at the points provid

ed for the system concerned (e.g. open threaded vent plugs, pump until no bubbles can be discernedin the oil, close threaded vent plugs).

During the installation procedure, screw on device with pushed-in plunger. During the removal procedure, screw on device with retracted plunger.For a hydraulic installation/removal tool with central expansion pressure supply, screw spindle into shaftend until correct sealing is established.During hydraulic installation/removal of components, ensure that no persons are in the direct vicinity ofthe component being pressed.Working on electrical/electronic assembliesBefore starting any maintenance or repair work, or before switching off any electronic components necessary to carry out the work, permission must first be obtained from the relevant manager or supervisor.Before work is carried out on the assemblies, the power supply to the relevant areas must be switchedoff.Do not damage wiring during the removal work. When reinstalling, ensure that the wiring cannot be damaged during engine operation through contact with sharp edges, rubbing against a component or throughcontact with a hot surface.Do not secure cables on lines carrying fluids.Do not use cable clamps to secure the lines.Only tighten union nuts of connectors with connector pliers.On completion of all repair work, the device or system must undergo a function check.Before replacement, ensure that spare parts are correctly stored, i.e. in particular, protected againstmoisture. Defective electronic components and assemblies must be suitably packed when dispatched forrepair, i.e. in particular, protected against moisture and impact and wrapped in antistatic foil if necessary.Work with laser devicesWhen working with laser equipment, always wear special laser-protection goggles eye injury throughstrongly concentrated beam.Laser devices must be equipped, in accordance with their class and usage, with protective devices forensuring safe operation.For conducting light-beam procedures and measurement work, only the following laser devices may beused: Laser devices in classes 1, 2 or 3A. Laser devices of class 3B, which have maximum output in the visible wavelength range (400 to 700

nm), a maximum output of 5 mW, and in which the beam axis and surface have been designed insuch a way as to prevent any risk to the eyes.

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1.6 Auxiliary materials, fire prevention and environmentalprotectionFire preventionRectify any fuel or oil leaks immediately; even splashes of oil or fuel on hot components can cause fires -therefore always keep the engine in a clean condition. Do not leave cloths soaked with fluids and lubricants lying around on the engine. Do not store combustible fluids near the engine.Do not weld pipes and components carrying oil or fuel. Before welding, clean with a non-combustiblefluid.When starting the engine with a foreign power source, connect the ground lead last and remove it first.To avoid sparks in the vicinity of the battery, connect the ground lead from the foreign power source tothe ground lead of the engine or to the ground terminal of the starter.Always keep suitable fire-fighting equipment (fire extinguishers) at hand and familiarize yourself with theiruse.SOLAS classificationOn engines/plants with SOLAS classification, operational checks must include the following tasks: Check all covers (fitted in accordance with SOLAS requirements) on lube oil and fuel pipe connections

(>1.8 bar) for damage, replace as necessary. ( Page 18)NoiseNoise can lead to an increased risk of accident if acoustic signals, warning shouts or noises indicatingdanger are drowned.At all workplaces with a sound pressure level over 85 dB(A), always wear ear protectors (protective wadding, plugs or capsules).Environmental protectionModification or removal of mechanical or electronic components or the installation of additional components as well as the execution of calibration processes that might affect the emission characteristics ofthe engine are prohibited by emission regulations. Emission control units/systems may only be maintained, exchanged or repaired if the components used for this purpose are approved by MTU or equivalent components. Noncompliance with these guidelines might represent a violation of the Clean Air Actand could involve the termination of the operating license by the emission authorities. MTU does not accept any liability for violations of the emission regulations. MTU will provide assistance and advice ifemission-relevant components are intended to be modified. The MTU Maintenance Schedules ensurethe reliability and performance of MTU engines and must be complied with over the entire life cycle of theengine.Only fuels of the specified quality required to achieve emission limits must be used.In Germany, the VAwS (=regulations governing the use of plants that may affect water quality) is applicable, which means work must only be carried out by authorized specialist companies (MTU is an authorized specialist company).Dispose of used fluids, lubricants and filters in accordance with local regulations.Auxiliary materialsUse only fluids and lubricants that have been tested and approved by MTU.Fluids and lubricants must be kept in suitable, properly designated containers. When using fluids, lubricants and other chemical substances, follow the safety instructions applicable to the product. Take carewhen handling hot, chilled or caustic materials. When using inflammable materials, avoid sparks and donot smoke.

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Lead When working with lead or lead-containing pastes, avoid direct contact with the skin and do not inhale

lead vapors. Adopt suitable measures to avoid the formation of lead dust! Switch on fume extraction system. After coming into contact with lead or lead-containing materials, wash hands!Acids and alkaline solutions When working with acids and alkalis, wear protective goggles or face mask, gloves and protective

clothing. Immediately remove clothing wetted by acids and alkalis! Rinse injuries with plenty of water! Rinse eyes immediately with eyedrops or clean tap water.Painting When painting in other than spray booths equipped with extractors, ensure good ventilation. Make

sure that adjacent work areas are not affected. No naked flames! No smoking. Observe fire prevention regulations! It is absolutely necessary to wear masks providing protection against paint and solvent fumes.Liquid nitrogen Store liquid nitrogen only in small quantities and always in regulation containers without fixed covers. Do not bring liquid nitrogen in contact with the body (eyes, hands), as this causes frostbite and numb

ing. Wear protective clothing, gloves, closed shoes and protective goggles! Ensure the room is well ventilated. 88% contamination of breathing air with nitrogen will result in suffo

cation. Avoid all knocks and jars to the containers, fixtures or workpieces.Compressed airCompressed air is air compressed at excess pressure and is stored in tanks from which it can be extracted.The pressure at which the air is kept can be read off at pressure gauges which must be connected to thecompressed air tanks and the compressed air lines.When working with compressed air, safety precautions must be constantly observed: Pay special attention to the pressure level in the compressed air network and pressure vessel! Connecting devices and equipment must either be designed for this pressure or, if the permitted pres

sure for the connecting elements is lower than the pressure required, a pressure reducing valve andsafety valve (set to permitted pressure) must form an intermediate connection. Hose coupling andconnections must be securely attached!

Always wear protective goggles when blowing off tools or extracting chips! The snout of the air nozzle is provided with a protective disc (e.g. rubber disc), which prevents air-

borne particles being reflected and thereby prevents injury to eyes. First shut off compressed air lines before compressed air equipment is disconnected from the supply

line or before equipment or tool is to be replaced! Unauthorized use of compressed air, e.g. forcing flammable liquids (danger class AI, AII and B) out of

containers, results in a risk of explosion! Forcing compressed air into thin-walled containers (e.g. sheet metal, plastic, glass) for drying purpos

es or to check for leaks will result in a risk of bursting! Do not blow dirty clothing with compressed air when being worn on the body.

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Used oilUsed oil may contain health-threatening combustion residues.Rub barrier cream into hands! Wash hands after contact with used oil.

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1.7 Conventions for safety instructions in the textDANGER In the event of immediate danger.

Consequences: Death or serious injury Remedial action

WARNING In the event of potentially dangerous situations.Consequences: Death or serious injury Remedial action

CAUTION In the event of dangerous situations.Consequences: Minor injury or material damage Remedial action

Note: This manual contains highlighted safety warnings in accordance with the US ANSI Z535 standard whichbegin with one of the signal words listed above depending on the severity of the hazard.

Safety instructions1. Read and familiarize yourself with all safety notices before starting up or repairing the product.2. Pass on all safety instructions to your operating, maintenance, repair and transport personnel.

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2 General Information2.1 Engine side and cylinder designations

Engine sides are always designated as viewed from the driving end (KS).The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end ofthe engine.Other components are numbered in the same way, i.e. starting with No. 1 on driving end.

1 KGS = Free end2 Right engine side

3 KS = Driving end4 Left engine side

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2.2 Product descriptionDescription of the engineEngineThe engine is a liquid-cooled four-stroke diesel engine with c.c.w. direction of rotation, direct injection,sequential turbocharging and charge-air cooling.An electronic management system provides engine control and monitoring.Fuel system with common rail injectionControlled by the engine electronics, the common rail injection system determines injection pressure, injection timing and injection quantity independently of the engine speed.Injection pressures up to 1800 bar ensure optimum fuel injection and combustion conditions.Charging systemThe charging system comprises charge-air system, exhaust system and sequential turbocharging.The exhaust system is equipped with triple-walled, water-cooled exhaust lines.The triple-walled design permits low surface temperature, reduced thermal load, absolute gas-tightness.Lube oil systemWet-sump forced-feed lubrication systemComponents supplied with oil: Bearings Piston cooling Control and actuating elements of the sequential turbocharging systemCooling system Two separate cooling circuits:

Engine coolant Raw water

Coolant cooling by raw water-cooled plate-core heat exchanger Thermostat-controlled coolant system Coolant-cooled / preheated charge air Coolant-cooled fuel returnElectronic systemElectronic control and monitoring system with integrated security and test system with interfaces to remote control system (RCS) and to monitoring system (MCS).Electronic engine control unit (ECU)Closed-loop control: Engine speed Fuel HP

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Open-loop control: Injection (fuel pressure, injection timing, injection duration, operating status) Sequential turbocharging (cutting-in and out) with secondary turbocharger Engine protection with multi-stage safety systems:

Power reduction Power limitation Emergency stop

Monitoring: Exhaust gas temperature, A-side Exhaust temperature, B-side Engine speed Oil pressure Differential oil pressure Coolant temperature Coolant level Exhaust turbocharger speed Leak fuel level Oil temperature Coolant pressure Fuel pressure after filterMonitoring in engine roomEngine control and monitoring unit (LOP)Functions: Engine speed, oil pressure and coolant temperature are monitored and displayed Integrated safety system Integrated test system Redundant CAN bus interface to governor and higher-level control and monitoring system 24 V DC power supply


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SOLAS Fire protection specificationsSpecial connections

In case of leakage, the above-mentioned connection types are spray-protected even without a cover andhave been confirmed compliant with SOLAS by GL and DNV.Plug-in pipe connectionThe sleeve (4) covers the joint to prevent lateral spray.Only leak-off along the line is possible, the pressure is decreased significantly if an O-ring (3) defect occurs.The connection is confirmed as compliant with SOLAS by DNV and GL.Plugs and sensorsScrew-in plugs (2) are sealed toward the outside either with a copper sealing ring (1), according to DIN,or an O-ring (ISO).In case of a loose single-ended union or a defective sealing ring (2), the liquid first has to pass thethread.


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The pressure is so greatly reduced by this and the faulty sealing ring (2) that any leakage is not underpressure.HP line between fuel injector and HP accumulator

1 Support ring2 V-ring3 Thrust ring

4 Union nut5 HP line6 Thrust screw

7 Thrust ring8 V-ring9 Support ring


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HP line between distributor and HP accumulator

1 Union nut2 O-ring3 Thrust ring

4 Thrust screw5 O-ring6 O-ring

7 Thrust ring8 Pressure pipe9 Jacket pipe


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HP line between distributor and HP accumulator

1 Jacket pipe2 O-ring3 O-ring4 Thrust ring

5 Thrust screw6 Thrust ring7 O-ring8 HP line

9 Pressure pipe10 O-ring

Leak fuel caused by leakages from the sealing cones or the HP lines is returned to the HP pump, fromwhere it is routed at atmospheric pressure into a level-monitored leak fuel tank.


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2.3 Engine layoutEngine layout

1 Engine oil heat exchanger

2 Engine oil filter3 Engine coolant filter4 Change-over lever for en

gine oil filter5 Fuel cooler6 Coolant distribution hous

ing with integral expansion tank

7 Engine hoisting lug (freeend)

8 Electronic engine management system

9 Air filter10 Air intake11 Air collector housing

(shroud)12 Exhaust turbocharger,

right (secondary turbocharger)

13 Carrier housing14 Exhaust turbocharger

(primary turbocharger)15 Exhaust turbocharger, left

(secondary turbocharger)16 Exhaust outlet (horizon

tal)17 Actuating cylinder for ex

haust flap18 Actuating cylinder for air

flap19 Control valve for flap con

trol20 Cylinder head cover21 Exhaust manifold22 Engine mounting23 Electric starter24 Oil pan25 Battery-charging genera

tor

26 Raw-water connection forgearbox cooling

27 Gearcase28 Raw water pump29 Raw-water connection

from sea30 Raw water connection to

sea31 Plate-core heat exchang

er32 Thermostat housing33 Fuel priming pump34 Fuel duplex filter (switch

able)KGS = free end


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1 Exhaust turbocharger, left(secondary turbocharger)

2 Exhaust turbocharger(primary turbocharger)

3 Air intake4 Engine hoisting lug (driv

ing end)5 Exhaust turbocharger,

right (secondary turbocharger)

6 Engine coolant filler neck7 Crankcase breather8 Change-over lever for en

gine oil filter

9 Engine coolant filter10 Engine oil filter11 Fuel filter12 Engine oil heat exchang

er13 Coolant distribution hous

ing with integral expansion tank

14 Thermostat housing15 Exhaust manifold16 Coolant pump17 HP fuel pump18 Fuel delivery pump19 Oil filler neck

20 Oil dipstick21 Drive flange22 Flywheel housing23 Engine mounting24 Carrier housing core25 Carrier housing lower

part26 Exhaust outlet27 Carrier housing upper

partKS = driving end

Engine model designationKey to the model designation 12V/16V 2000 Mxy 12/16 = Number of cylinders V = Cylinder arrangement 2000 = Series Mx = application segment y = design index


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2.4 Sensors, actuators and injectors OverviewEngine plan viewDeviations from illustrations are insignificant.Also applies similarly to 12V.

Item Description Monitoring of1 B7 Lube oil temperature2 B10 Charge-air pressure3 B44 Turbocharger speed4 B3 Intake air temperature5 B9 Charge-air temperature


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Engine free end

Item Description Monitoring of1 B34 Fuel pressure after filter2 B5.3 (option) Lube oil pressure before filter3 B5.1 Lube oil pressure after filter4 B5.2 (option) Lube oil pressure after filter5 F33 Engine coolant level, expansion tank6 B21 (option) Raw water pressure7 B6.2 (option) Coolant temperature8 B6.1 Coolant temperature


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Engine driving end

Item Description Monitoring of1 B1 (ECU) Camshaft speed2 B13.2 (optional EMU) Crankshaft speed3 B13 (ECU) Crankshaft speed


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Engine, right side

Item Description Monitoring of1 YB33 Fuel temperature2 B48 Fuel pressure (in rail)3 B16 (option) Coolant pressure4 F46 Leak fuel level5 Y27.2 4-2-directional control valve, B-side6 B4.22 Exhaust temperature, B-side7 F41 2-2-directional control valve


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Engine, left side

Item Description Monitoring of1 B4.21 Exhaust gas temperature, A-side2 Y27.1 4-2-directional control valve, A-side3 B54 (option) Lube oil pressure, replenishment pump

System sensorsThese sensors are fitted outside the engine.Description Monitoring ofB19 Starting-air pressureB70 Fuel prefilter water levelB41 Exhaust back pressureS37 Start interlock, switching status


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3 Technical Data3.1 12V 2000 M72 engine data: Engine-mounted heat

exchanger, EPA stage 2Explanation:

DL Ref. value: Continuous powerBL Ref. value: Fuel stop power

A Design valueG Guaranteed valueR Guideline valueL Limit value, up to which the engine can be operated, without change (e.g. of power settings).N Not yet defined value- Not applicable

X ApplicableREFERENCE CONDITIONSEngine model 12V 2000

M72Application group 1BIntake air temperature C 25Raw water inlet temperature C 25Barometric pressure mbar 1000Site altitude above sea level m 100

POWER-RELATED DATA (power ratings are net brake power as per ISO 3046)Number of cylinders 12Rated engine speed A rpm 2250Fuel stop power ISO 3046 A kW 1080

GENERAL CONDITIONS (for maximum power)Number of cylinders 12Intake air depression (new filter) A mbar 15Intake air depression, max. L mbar 30

MODEL RELATED DATA (basic design)Number of cylinders 12Cylinder arrangement: V angle degrees 90Bore mm 135Stroke mm 156Cylinder displacement liters 2.23Total displacement liters 26.76

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Number of cylinders 12Inlet valves per cylinder 2Exhaust valves per cylinder 2

RAW-WATER CIRCUIT (open circuit)Number of cylinders 12Raw water pump: Inlet pressure, min. L bar -0.4Raw water pump: Inlet pressure, max. L bar +0.5Pressure loss in off-engine raw-water system, max. L bar 0.7

LUBE OIL SYSTEMNumber of cylinders 12Lube oil operating temperature before engine, from R C 78Lube oil operating temperature before engine, to R C 88Lube oil operating pressure before engine, from R bar 7.8Lube oil operating pressure before engine, to R bar 8.8Lube oil operating pressure, low idle (meas. point: before engine) R bar 3.0

FUEL SYSTEMNumber of cylinders 12Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.3Fuel pressure at supply connection to engine (when engine is running),min.

L bar -0.3

Fuel pressure at engine inlet connection, max. (when engine is starting) L bar +0.25Fuel supply flow, max. R liter/min 4.6

GENERAL OPERATING DATANumber of cylinders 12Firing speed, from R rpm 100Firing speed, to R rpm 200

STARTING (electric)Number of cylinders 12Rated starter voltage (standard design) R V= 24

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INCLINATIONS, STANDARD OIL SYSTEM (Reference: waterline)Number of cylinders 12Longitudinal inclination, continuous max., driving end down (Option: max.operating inclinations)

L degrees 15

Longitudinal inclination, temporary max., driving end down (Option: max.operating inclinations)

L degrees 22.5

Longitudinal inclination, temporary max., driving end up (Option: max. operating inclinations)

L degrees 10

Transverse inclination, continuous max. (Option: max. operating inclinations)

L degrees 22.5

Transverse inclination, temporary max. (Option: max. operating inclinations) L degrees 32.5CAPACITIESNumber of cylinders 12Engine coolant, engine-side (with cooler) R liters 125Total engine oil capacity at initial filling (standard oil system) (Option: max.operating inclinations)

R liters 123

Oil change quantity, max. (standard oil system) (Option: max. operating inclinations)

R liters 113

Oil pan capacity at dipstick mark "min." (standard oil system) (Option: max.operating inclinations)

L liters 87

Oil pan capacity at dipstick mark "max." (standard oil system) (Option: max.operating inclinations)

L liters 105

WEIGHTS / MAIN DIMENSIONSNumber of cylinders 12Engine dry weight (with attached standard accessories, without coupling) R kg 2780

ACOUSTICSNumber of cylinders 12Exhaust noise, unsilenced, BL, (free-field sound-pressure level Lp, 1m distance, ISO 6798)

R dB(A) 105

Engine surface noise with attenuated intake noise (filter), BL, (free-fieldsound-pressure level Lp, 1m distance, ISO 6798)

R dB(A) 102


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3.2 12 V 2000 M72 engine data: remote heat exchanger, EPAstage 2Explanation:


A Design valueG Guaranteed valueR Guideline valueL Limit value, up to which the engine can be operated, without change (e.g. of power setting)N Not yet defined value- Not applicable

X ApplicableREFERENCE CONDITIONSEngine model 12V2000



GENERAL CONDITIONS (for maximum power)Number of cylinders 12Intake depression (new filter) A mbar 15Intake depression, max. L mbar 30

MODEL RELATED DATA (basic design)Number of cylinders 12Cylinder arrangement: V angle Degrees 90Bore mm 135Stroke mm 156Cylinder displacement Liters 2.23Total displacement Liters 26.76Number of inlet valves per cylinder 2Number of exhaust valves per cylinder 2


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LUBE OIL SYSTEMNumber of cylinders 12Lube oil operating temperature before engine, from R C 79Lube oil operating temperature before engine, to R C 89Lube oil operating pressure before engine, from R bar 7.8Lube oil operating pressure before engine, to R bar 8.8Lube oil operating pressure (low idle) (meas. point: before engine) R bar 3.0

FUEL SYSTEMNumber of cylinders 12Fuel pressure at engine inlet connection, min. (when engine is starting) L bar -0.3Fuel pressure at engine inlet connection, min. (when engine is running), L bar -0.3Fuel pressure at engine inlet connection (when engine is starting), max. L bar +0.25Fuel supply flow, max. R Liters/min 4.6


STARTER (electric)Number of cylinders 12Rated starter voltage (standard design) R V= 24

INCLINATIONS, STANDARD OIL SYSTEM (reference: waterline)Number of cylinders 12Longitudinal inclination, continuous max. driving end down (option: max.operating inclinations)

L Degrees 15

Longitudinal inclination, temporary max. driving end down (option: max. operating inclinations)

L Degrees 22.5

Longitudinal inclination, temporary max., driving end up (option: max. operating inclinations)

L Degrees 10

Transverse inclination, continuous max. (option: max. operating inclinations)

L Degrees 22.5

Transverse inclination, temporary max. (option: max. operating inclinations) L Degrees 32.5


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CAPACITIESNumber of cylinders 12Engine oil capacity, initial filling (standard oil system) (option: max. operating inclinations)

R Liters 123

Oil change quantity, max. (standard oil system) (option: max. operating inclinations)

R Liters 113

Oil pan capacity at dipstick mark min. (standard oil system) (option: max.operating inclinations)

L Liters 87

Oil pan capacity at dipstick mark max. (standard oil system) (option: max.operating inclinations)

L Liters 105


ACOUSTICSNumber of cylinders 12Exhaust noise, unsilenced,BL, (free-field sound-pressure level Lp, 1m distance, ISO 6798)

R dB(A) 105

Engine surface noise with attenuated intake noise (filter) - BL (free-fieldsound pressure level Lp, 1m distance, ISO 6798)

R dB(A) 102


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3.3 16V 2000 M72 engine data: Engine-mounted heatexchanger, EPA stage 2Explanation:







MODEL RELATED DATA (basic design)Number of cylinders 16Cylinder arrangement: V angle degrees 90Bore mm 135Stroke mm 156Cylinder displacement liters 2.23Total displacement liters 35.68Inlet valves per cylinder 2Exhaust valves per cylinder 2


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RAW-WATER CIRCUIT (open circuit)Number of cylinders 16Raw water pump: Inlet pressure, min. L bar -0.4Raw water pump: Inlet pressure, max. L bar +0.5Pressure loss in off-engine raw-water system, max. L bar 0.7



L bar -0.3





L degrees 15


L degrees 22.5


L degrees 10


L degrees 22.5

Transverse inclination, temporary max. (Option: max. operating inclinations) L degrees 32.5


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CAPACITIESNumber of cylinders 16Engine coolant, engine-side (with cooler) R liters 135Total engine oil capacity at initial filling (standard oil system) (Option: max.operating inclinations)

R liters 168


R liters 155


L liters 115


L liters 138



R dB(A) 108


R dB(A) 105


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3.4 16V 2000 M72 engine data: Separate heat exchanger, EPAstage 2Explanation:







MODEL RELATED DATA (basic design)Number of cylinders 16Cylinder arrangement: V angle degrees 90Bore mm 135Stroke mm 156Cylinder displacement liters 2.23Total displacement liters 35.68Inlet valves per cylinder 2Exhaust valves per cylinder 2


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L bar -0.3





L degrees 15


L degrees 22.5


L degrees 10


L degrees 22.5

Transverse inclination, temporary max. (Option: max. operating inclinations) L degrees 32.5


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CAPACITIESNumber of cylinders 16Total engine oil capacity at initial filling (standard oil system) (Option: max.operating inclinations)

R liters 168


R liters 155


L liters 115


L liters 138



R dB(A) 108


R dB(A) 105


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3.5 Firing orderFiring order8V A1-B4-A4-A2-B3-A3-B2-B110 V A1-B4-A4-B3-A3-B2-A2-B5-A5-B112 V A1-B5-A5-B3-A3-B6-A6-B2-A2-B4-A4-B116 V A1-B5-A3-A5-B2-B8-A2-A8-B3-A7-B4-B6-A4-A6-B1-B7


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3.6 Engine Main dimensionsMain dimensions

Engine model Length (A) Width (B) Height (C)8V 2000 M72 approx. 1683 mm approx. 1147 mm approx. 1200 mm8V 2000 M92 approx. 1683 mm approx. 1147 mm approx. 1200 mm8V 2000 M93 approx. 1683 mm approx. 1147 mm approx. 1200 mm8V 2000 M84 approx. 1683 mm approx. 1147 mm approx. 1200 mm8V 2000 M94 approx. 1683 mm approx. 1147 mm approx. 1200 mm10V 2000 M72 approx. 1860 mm approx. 1147 mm approx. 1320 mm10V 2000 M92 approx. 1860 mm approx. 1147 mm approx. 1320 mm10V 2000 M93 approx. 1860 mm approx. 1147 mm approx. 1320 mm10V 2000 M84 approx. 1860 mm approx. 1147 mm approx. 1320 mm10V 2000 M94 approx. 1860 mm approx. 1147 mm approx. 1320 mm12V 2000 M92 approx. 2069 mm approx. 1295 mm approx. 1350 mm12V 2000 M93 approx. 2069 mm approx. 1295 mm approx. 1350 mm12V 2000 M84 approx. 2094 mm approx. 1295 mm approx. 1350 mm12V 2000 M94 approx. 2094 mm approx. 1295 mm approx. 1350 mm16V 2000 M92 approx. 2486 mm approx. 1295 mm approx. 1390 mm16V 2000 M93 approx. 2486 mm approx. 1295 mm approx. 1390 mm16V 2000 M84 approx. 2511 mm approx. 1295 mm approx. 1390 mm16V 2000 M94 approx. 2511 mm approx. 1295 mm approx. 1390 mm


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4 Operation4.1 Engine Putting the engine into operation (out of service > 3

months)Preconditions Engine is stopped and starting disabled. MTU Fluids and Lubricants Specifications (A001061/..) are available.Putting the engine into operation (out-of-service period > 3 months)Item MeasureEngine Depreserve ( MTU Fluids and Lubricants Specifications A001061/..).Lube oil system Check engine oil level ( Page 102).Fuel prefilter Fill with fuel ( Page 95).

Align adjustable pointer with position of pressure indicator ( Page 91).Fuel system Vent ( Page 88).Raw water pump (if locatedabove waterline)

Fill with water (approx. 3 4 liters).Filling point ( Page 109).

Coolant circuit If engine is out of service for more than one year, change engine coolant( Page 116).Check coolant level ( Page 115).Heat engine coolant with coolant preheating unit.

Engine control system Switch on ( Operating Instructions for BlueVision).Engine Start ( Operating Instructions for BlueVision ).

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4.2 Putting the engine into operation after scheduled out-of-service periodPreconditions Engine is stopped and starting disabled.StartupItem TaskLube oil system Check oil level ( Page 102).Coolant system Check coolant level ( Page 115).Coolant system Preheat coolant with preheating unit.Fuel prefilter Drain ( Page 92).Battery-charging generatordrive

Check condition of drive belt ( Page 123).Engine control system Switch on ( Operating instructions BlueVision ).Engine Start ( Operating instructions BlueVision ).

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4.3 Tasks after extended out-of-service periods (>3 weeks)Tasks after extended out-of-service periods (>3 weeks)

Note: Operate fuel treatment system for at least 5 minutes.1. Start up fuel treatment system ( Page 49).2. Shut down fuel treatment system ( Page 57).

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4.4 Checks prior to start-upChecks prior to start-up

1. Check tank and the entire pipework for cleanness. If microorganisms are detected:a) Clean affected components.b) Disinfect affected components with biocides ( MTU Fluids and Lubricants Specifications

A001061/..).2. Close drain valves on housing.3. Open all supply and discharge valves.4. Switch on fuel treatment system ( Page 52).5. Check direction of rotation of pump.6. Vent bypass and fuel lines of the system.

a) Open ball valve for pressure tank.b) Open ball valve for overflow tank.c) Close ball valve at the inlet to the fuel treatment system.

Result: Bypass line is vented via the overflow tank.d) Open ball valve at the inlet to the fuel treatment system.

7. Check the fuel treatment system for leaks.Result: The fuel treatment system is ready for operation.

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4.5 Fuel treatment system Start-upFuel treatment system Overview

1. Switch on fuel treatment system ( Page 52).2. Check the differential pressure at differential pressure gauge (8). Differential pressure in a new system:

0.1 bar to 0.3 bar.Result: If no differential pressure is measured, the coalescer filter element is probably being bypassed.

1. Remove coalescer filter element ( Page 129).2. Check sealing faces on coalescer filter element and in the pressure tank.

Initial operation: HAT1. Replace fuel filter on engine ( Page 89).

Note: Determine the suction pressure upstream of the engine-mounted fuel delivery pump.2. Install a pressure gauge in the fuel supply line from the ship-side fuel system to the engine.3. Switch on fuel treatment system and operate it for some minutes ( Page 52).

Result: Fuel is sucked from the tank, dirt particles and water are filtered and separated, then the fuel is deliveredvia the overflow tank back to the tank. Water which has settled in the tank is separated.

4. Start engine ( Page 53).5. Run engine at idling speed.6. Check suction pressure (see technical data of the engine) at the engine-mounted fuel delivery pump.

Note: If the suction pressure is within the permissible limits and engine operation is satisfactory:7. Increase engine speed to 1000 rpm and monitor suction pressure.8. Check suction pressure at the engine-mounted fuel delivery pump.

Result: If the values are within the limits specified by the manufacturer, the system is ready to start filter replacement simulation with the engine running as part of the Harbor Acceptance Tests.

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Simulation of filter replacement with the engine running: HAT1. Switch on fuel treatment system ( Page 52).2. Start engine ( Page 53).3. Run engine at idling speed.4. Close ball cock (5) at the inlet to the fuel treatment system.

Result: The pressure upstream of the fuel treatment system increases until the overflow valve at the pump unitopens and fuel flows through bypass (3) and bypass (2).

5. Open ball cock (19).Result: Fuel emerges. If no fuel emerges:

Open ball cock (5) at the inlet to the fuel treatment system. No function of bypasses (2) and (3); carry out functional test of bypasses (2) and (3) .

6. Check suction pressure (see technical data of the engine) at the fuel delivery pump.Note: If the suction pressure is within the permissible limits and engine operation is satisfactory:

7. Increase engine speed to 1000 rpm and monitor suction pressure.Result: If all engine operating values are within the specified limits, open ball cock (5) at the inlet to the fuel treat

ment system.Simulation of power failure (emergency): HAT

1. Switch on fuel treatment system ( Page 52).2. Start engine ( Page 53).3. Run engine at idling speed.4. Switch off pump (21) on switchgear cabinet.

Result: The engine-mounted fuel delivery pump sucks fuel via bypass (2) directly from the tank.5. Check suction pressure at the engine-mounted fuel delivery pump.

Note: If the suction pressure is within the permissible limits and engine operation is satisfactory:6. Increase engine speed to 1000 rpm and monitor suction pressure.

Result: If the suction pressure is within the specified limits, simulation was successful.Simulation of power failure (emergency): SAT

1. Switch on fuel treatment system ( Page 52).2. Start engine ( Page 53).3. Run engine at idling speed.4. Switch off pump (21) on switchgear cabinet.

Result: The engine-mounted fuel delivery pump sucks fuel via bypass (2) directly from the tank.5. Check suction pressure at the engine-mounted fuel delivery pump.

Note: If the suction pressure is within the permissible limits and engine operation is satisfactory:6. Operate engine at full load and monitor suction pressure.

Result: If the suction pressure is within the specified limits, simulation was successful.

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4.6 Operational checksDANGER Unguarded rotating and moving engine components.

Risk of serious injury danger to life! Take special care when working on a running engine.

WARNING Engine noise above 85 dB (A).Risk of damage to hearing! Wear ear protectors.

Operational checksItem MeasureEngine under loadEngine at nominal speed

Visually inspect engine for leaks and general condition;Check for abnormal running noises and vibration;Check exhaust color ( Page 61).

Fuel prefilter Check if suction-side pressure indicated at the fuel prefilter pressuregauge is within the limit ( Page 91).Drain water and contaminants ( Page 92).

Air filter Check signal ring position of service indicator ( Page 100).HT coolant pump Check relief bore for oil and coolant discharge and contamination

( Page 119).Raw water pump Check relief bore for oil and water discharge and contamination

( Page 122).Intercooler Check condensate drain (if applicable) ( Page 97).Engine oil Check engine oil level ( Page 102).

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4.7 Fuel treatment system Switching onPreconditions The on-board power supply is switched on.

CAUTION Damage to engine/plant.Major material damage! Before switching on, ensure that the engine/plant is ready for operation. Before switching on, ensure that all housings are closed. Before switching on, ensure that no work is in progress anywhere on the entire system.

Fuel treatment system Switching on1. Carry out checks prior to start-up ( Page 48).2. Switch on master switch on control cabinet.

Result: Signal lamp Control voltage present lights up.3. Switch on switch for pump.

Result: Signal lamp Pump running lights up.

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4.8 Starting the enginePreconditions External start interlock is not activated. Emergency air shut-off flaps (if fitted) are open.

DANGER Unguarded rotating and moving engine components.Risk of serious injury danger to life! Before barring or starting the engine, make sure that nobody is in the danger zone.

WARNING Engine noise above 85 dB (A).Risk of damage to hearing! Wear ear protectors.

The engine can be started from the following points :1. ( Operating instructions for electronic system)2. Commanding control stand ( Operating instructions for electronic system);3. Local operating panel LOP ( Operating instructions for electronic system);4. Local Operation Station LOS ( Operating instructions for electronic system);5. CCU ( Operating instructions for electronic system).

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4.9 Stopping the enginePreconditions Engine is running in local mode.

CAUTION Stopping the engine when it is running at full load causes extreme stress to the engine.Risk of overheating, damage to components! Before shutting down, disengage gear and run the engine at idle speed for at least 10 mins. until

engine temperatures have dropped and constant values are displayed.

The engine can be stopped from the following points :1. ( Operating instructions for electronic system)2. Commanding control stand ( Operating instructions for electronic system);3. Local operating panel LOP ( Operating instructions for electronic system);4. Local Operation Station LOS ( Operating instructions for electronic system);5. CCU ( Operating instructions for electronic system).

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4.10 Emergency stopCAUTION An emergency stop causes extreme stress to the engine.

Risk of overheating, damage to components! Initiate emergency stop only in emergency situations.

An emergency stop of the engine can be initiated from the following points :1. ( Operating instructions for electronic system)2. Commanding control stand ( Operating instructions for electronic system);3. Local operating panel LOP ( Operating instructions for electronic system);4. Local Operation Station LOS ( Operating instructions for electronic system);5. CCU ( Operating instructions for electronic system).

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4.11 After stopping the enginePreconditions MTU Fluids and Lubricants Specifications (A001061/..) are available.After stopping the engineItem ActionCoolant circuit Drain coolant ( Page 117) if:

freezing temperatures are expected and the engine is to remain out ofservice for an extended period, but engine coolant has no antifreezeadditive;

the engine room is not heated; the coolant is not kept at a suitable temperature; the antifreeze concentration is insufficient for the engine-room tempera

ture; antifreeze concentration is 50 % and engine-room temperature is below

-40 C.Raw water Drain

If freezing temperatures are to be expected and the engine is to remainout of service for an extended period.

Engine control system Switch off.Air intake and exhaust system

Out-of-service-period > 1 week Seal engine's air and exhaust sides.

Engine Out-of-service-period > 1 month Preserve engine ( MTU Fluids and Lubricants Specifications

A001061/.. )

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4.12 Fuel treatment system ShutdownFuel treatment system Shutdown

1. Press the illuminated pushbutton "Water drain" on the switchgear cabinet until water discharge from theoutlet stops.

2. Switch off fuel treatment system.3. Close ball valve at the inlet to the fuel treatment system.4. Close ball valve at the outlet of the fuel treatment system.5. Open drain valve until pressure has escaped from fuel treatment system.

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4.13 Plant CleaningPreconditions Engine is stopped and starting disabled. Operating voltage is not applied.Special tools, Material, Spare parts

Designation / Use Part No. Qty.Steam jet cleaner - 1Cleaner (Hakupur 312) 30390 1

WARNING Compressed airRisk of injury! Do not direct compressed-air jet at persons. Wear protective goggles / safety mask and ear protectors.

WARNING Water jet.Risk of injury and scalding! Do not direct water jet at persons. Wear protective clothing, gloves, and goggles / safety mask.

CAUTION Excessive reaction time of cleaning agents on components.Damage to component! Observe manufacturer's instructions. Wear protective clothing, gloves, and goggles / safety mask.

Note: There is a risk of damaging sensors with compressed air.Plant Cleaning

1. Carry out plant cleaning only in areas where an appropriate oil separator is provided (environmental protection).

2. Prior to putting the cleaning unit into operation, read the Operating Instructions of the water/steam jet unitcarefully and observe the safety precautions.

3. For external cleaning with high-pressure jet, use a flat-mouth nozzle only.4. Carry out external cleaning as follows:

a) Remove coarse dirt.b) Spray on cleaner sparingly and leave it for 1 to 5 minutes.c) Use the high-pressure jet to remove the loosened dirt.d) During external cleaning of the plant with water/steam-jet units, the pressure of the high-pressure jet

(cleaning jet) must not exceed 50 bar. A minimum distance between spray nozzle and plant of 1 mmust be observed. The temperature of the cleaning medium must not exceed 80C.

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5 Maintenance5.1 Maintenance task reference table [QL1]

The maintenance tasks and intervals for this product are defined in the Maintenance Schedule. TheMaintenance Schedule is a stand-alone publication.The task numbers in this table provide reference to the maintenance tasks specified in the MaintenanceSchedule.Task Maintenance tasksW0500 Check engine oil level ( Page 51)W0501 Visually inspect engine for leaks and general condition ( Page 51)W0502 Check intercooler drain (if fitted) ( Page 51)W0503 Check air filter service indicator ( Page 51)W0505 Check relief bores of coolant pump(s) ( Page 51)W0506 Check engine for abnormal running noises, exhaust color

and vibrations( Page 51)

W0507 Drain water and dirt from fuel prefilter (if fitted) ( Page 51)W0508 Check reading on differential pressure gauge of fuel prefilter

(if fitted)( Page 51)

W1001 Replace fuel filter or fuel filter element ( Page 89)W1002 Check valve clearance ( Page 81)W1003 Check drive belt condition and tension, replace as necessary ( Page 123)W1005 Replace air filter ( Page 98)W1006 Replace fuel injectors ( Page 85)W1008 Replace engine oil filter at each oil change or when the time

limit (years) is reached, at the latest( Page 104)

W1009 Check layer thickness of oil residue, clean and replace filtersleeve (if fitted)

( Page 106)

W1011 Perform endoscopic inspection of combustion chambers ( Page 74)W1036 Replace coolant filter ( Page 121)W1139 Replace paper or knitted fabric insert (if fitted) of oil mist sep

arator.( Page 79)

W1140 Clean wire meshes of crankcase breather ( Page 78)W1244 Check operation of rod electrode (if fitted) ( Page 127)W1245 Check alarm function of differential-pressure gauge(if fitted) ( Page 126)W1246 Check pump capacity (if fitted) ( Page 128)

Table 1: Maintenance task reference table [QL1]

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6 Troubleshooting6.1 Fuel treatment system Troubleshooting

Illuminated pushbutton Water alarm is lit.Cause Corrective actionWhen the maximum water levelis reached, the water level electrode opens the water drainvalve and water is discharged. Ifthe opening period of the valveexceeds a preset limit (4 minutes), the pump will switch offand an alarm is initiated.

1. Press illuminated pushbutton Water alarm to acknowledge.2. In addition to the automatic water drain function, water can also

be drained manually. To do so, press the illuminated pushbuttonWater drain to open the drain valve.

Signal lamp Pump fault is lit.Cause Corrective actionThe drive motor is equipped withan overload protection. If themaximum permissible currentconsumption is exceeded, e.g. incase of a blockage or dry-running, the motor protection relaytriggers and the pump is switched off.

u Reset motor protection relay.

Signal lamp Warning filter is lit.Cause Corrective actionThe differential pressure exceeded 1.3 bar.

u Replace coalescer filter element ( Page 129).

Illuminated pushbutton Replace filter element is lit.Cause Corrective actionThe max. permissible differentialpressure of 1.5 bar was exceeded. If the coalescer filter elementis not replaced, pressure will increase further and the safetyvalve will open. Fuel will be ledvia the bypass directly into theoverflow tank.

1. Replace coalescer filter element ( Page 129).2. Press illuminated pushbutton Replace filter element to ac

knowledge.

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6.2 TroubleshootingEngine does not turn when starter is actuatedComponent Probable Cause TaskBattery Low or defective Charge or replace (see manufacturer's

documentation).Cable connections defective Check if cable connections are proper

ly secured (see manufacturer's documentation).

Starter Engine wiring or starter defective Check if cable connections are properly secured, contact Service.

Engine wiring Defective Check ( Page 131).ECU Plug-in connections are loose Check plug-in connections for secure

seating.Engine Running gear blocked (engine cannot

be barred manually)Contact Service.

Engine turns but does not fireComponent Probable Cause TaskStarter Poor rotation by starter: Battery low or

defectiveCharge or replace battery (see manufacturer's documentation).

Engine wiring Defective Check ( Page 131).Fuel system Not vented Vent fuel system ( Page 88).ECU Defective Contact Service.

Engine fires unevenlyComponent Probable Cause TaskFuel injection equipment

Injector defective Replace ( Page 85).Engine wiring Defective Check ( Page 131).Fuel system Not vented Vent fuel system ( Page 88).ECU Defective Contact Service.

Engine does not reach nominal speedComponent Probable Cause TaskFuel supply Fuel prefilter clogged Replace ( Page 95).

Fuel filter clogged Replace ( Page 89).Air supply Air filter clogged Check signal ring position of service in

dicator ( Page 100).Fuel injection equipment

Injector defective Replace ( Page 85).Engine wiring Defective Check ( Page 131).Engine Overloaded Contact Service.

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Engine speed not steadyComponent Probable Cause TaskFuel injection equipment

Injector defective Replace ( Page 85).Speed sensor Defective Replace.Fuel system Not vented Vent fuel system ( Page 88).ECU Defective Contact Service.

Charge-air temperature too highComponent Probable Cause TaskEngine coolant Incorrect coolant concentration Check.Intercooler Contaminated Contact Service.Engine room Air-intake temperature too high Check fans and air supply / ventilation

ducts.

Charge air pressure too lowComponent Probable Cause TaskAir supply Air filter clogged Check signal ring position of service in

dicator ( Page 100).Intercooler Contaminated Contact Service.Exhaust turbocharger Defective Contact Service.

Coolant leaks on intercoolerComponent Probable Cause TaskIntercooler Leaking, major coolant discharge Contact Service.

Exhaust gas blackComponent Probable Cause TaskAir supply Air filter clogged Check signal ring position of service in

dicator ( Page 100).Fuel injection equipment

Injector defective Replace ( Page 85).Engine Overloaded Contact Service.

Exhaust gas blueComponent Probable Cause TaskEngine oil Too much oil in engine Drain engine oil ( Page 103).

Oil separator or oil preseparator ofcrankcase breather clogged

Clean preseparator ( Page 78). Replace filter element of oil separa

tor ( Page 79).Exhaust turbocharger, cylinder head, piston rings, cylinder liner

Defective Contact Service.

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Exhaust gas whiteComponent Probable Cause TaskEngine Not at operating temperature Run engine to reach operating temper

ature.Fuel system Water in fuel Drain fuel prefilter ( Page 92).Intercooler Leaking Contact Service.

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7 Task Description7.1 SOLAS

7.1.1 SOLAS shielding as per MTN 5233 Installation

Preconditions Engine is stopped and starting disabled.Special tools, Material, Spare parts

Designation / Use Part No. Qty.Shield A4 735233000100 10Shield A5 735233000101 14Shield A7 735233000103 6Shield A8 735233000104 2

Installing SOLAS shielding1. Pinpoint installation location ( Page 66).2. Install suitable shielding.3. Press shielding until locked.

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7.1.2 SOLAS shielding - Installation

Preconditions Engine shut down and starting disabled. Engine cooled down to ambient temperature.Special tools, Material, Spare parts

Designation / Use Part No. Qty.Oil filter shield X00009628Fuel filter shield X00009654

Installing SOLAS shield on oil filterand fuel filter

1. Pinpoint installation location ( Page 66).2. Install suitable shielding.

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7.1.3 Installation locations for SOLAS shielding

GeneralPrimarily fit SOLAS shielding as per MTN 5233 ( Page 64).Free end B-side

Item Type of shielding Comments1Free endB-side

Shield (A7) On fuel delivery pump

2Free endB-side

Shield (A7) On HP fuel pump

Free end


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Item Type of shielding Comments1Free end

Shield (A8) On fuel filter

2Free end

Shield (A7) Above fuel priming pump

3Free end

Shield (A7) Below fuel priming pump

Driving end A-side

Item Type of shielding Comments1Driving endA-side

Shield (A5) On air flap

2Driving endA-side

Shield (A4) On brazed-on union

3Driving endA-side

Shield (A5) On turbocharger flap

4Driving endA-side

Shield (A5) On turbocharger flap


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Driving end A-side

Item Type of shielding Comments1Driving endA-side

Shield (A5) To turbocharger relubrication

2Driving endA-side

Shield (A5) On valve plate

Driving end


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Item Type of shielding Comments1Drivingend

Shield (A4) Turbocharger lubrication, left side

2Drivingend

Shield (A4) Turbocharger lunrivation, center

Driving end

Item Type of shielding Comments1Drivingend

Shield (A4) Turbocharger lubrication, right side

Driving end B-side


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Item Type of shielding Comments1Drivingend B-side

Shield (A5) Turbocharger flap

2Drivingend B-side

Shield (A5) Turbocharger flap

3Drivingend B-side

Shield (A4) On brazed-on union

4Drivingend B-side

Shield (A5) On air flap

5Drivingend B-side

Shield (A4) To turbocharger relubrication

Driving end B-side


Shield (A5) On valve plate


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Driving end A-side

Item Type of shielding Comments1Drivingend A-side

Shield (A5) To flap control

Driving end B-side


Shield (A5) To flap control


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7.2 Engine7.2.1 Engine Barring manually


Designation / Use Part No. Qty.Barring tool F6783914 1Ratchet F30006212 1

DANGER Unguarded rotating and moving engine components.Risk of serious injury danger to life! before barring or starting the engine, ensure that nobody is in the danger zone. After working on the engine, check that all protective devices have been reinstalled and all tools

removed from the engine.

Engine Barring manually1. Fit ratchet with barring tool on barring tool connection at the vibration damper on engine free end.2. Rotate crankshaft in engine direction of rotation. Apart from the normal compression resistance, there

should be no resistance.Result: If the resistance exceeds the normal compression resistance, contact Service.


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7.2.2 Engine Barring with starting system

Preconditions Clutch is disengaged. Engine start is disabled. LOP is accessible and open.

DANGER Unguarded rotating and moving engine components.Risk of serious injury danger to life! before barring or starting the engine, ensure that nobody is in the danger zone. After working on the engine, check that all protective devices have been reinstalled and all tools

removed from the engine.

Barring1. Press barring button on the LMB mother

board of the LOP and keep it depressed.Result: Engine is barred by starter for max. 20 sec

onds.2. Release barring button.


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7.3 Cylinder Liner7.3.1 Cylinder liner Endoscopic examination

Preconditions Engine is stopped and starting disabledSpecial tools, Material, Spare parts

Designation / Use Part No. Qty.Rigid endoscope Y20097353 1

Preparatory steps1. Remove cylinder head cover ( Page 84).2. Remove injector ( Page 86).

Positioning crankshaft at BDC1. Using barring device, turn crankshaft until crankshaft journal of the cylinder to be tested has reached

BDC.2. Insert endoscope into cylinder liner through injector seat.

Endoscopic examination of cylinder linerFindings Measure Thin carbon coating on circumference of carbon scraper ring Slight localized additive deposits at top edge Localized smooth areas at bottom edge Carbon deposits on circumference in clearance between top piston

ring and bottom edge of carbon scraper ring First signs of marks left by top piston ring Bright mark on entire circumference Consistent honing pattern without objections First signs of marks left by lower cooling bores Running pattern seems darker

No action required

Dark areas with even or varying degrees of discoloration Beginning and end of the discoloration are not sharply defined and

do not cover the entire stroke area Dark areas in the upper section of the cooling bore, remaining cir

cumference without objections Piston rings without objections

Further endoscopic examination required as part of maintenance work

On the entire circumference, apart from light areas of discoloration(that do not impair operation) clearly darker stripes that start at thetop piston ring

Heat discoloration in the direction of stroke and honing pattern damage

Heat discoloration of piston rings

Cylinder liner must be replaced; Service must be contacted

1. Compile endoscopic report using the table.2. Use technical terms for description of the liner surface ( Page 76).3. Depending on findings:

Do not take any action or carry out a further endoscopic examination as part of maintenance work or contact Service; cylinder liner must be replaced.


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Final steps1. Install injector ( Page 86).2. Install cylinder head cover ( Page 84).


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7.3.2 Instructions and comments on endoscopic and visual examination of cylinderliners

Terms used for endoscopic examinationUse the terms listed below to describe the condition of the cylinder-liner surface in the endoscopic examination report.Finding ActionMinor dirt scores Minor dirt scores can occur during the assembly of a new engine (honing prod

ucts, particles, broken-off burrs). Removed cylinders clearly show such scoringon the running surface under endoscope magnification. Cannot be felt with thefingernail.Findings not critical.

Single scores Clearly visible scores from hard particles. They usually start in the TDC areaand cross through the hone pattern in the direction of stroke.Findings not critical.

Scored area These areas consist of scores of different length and depth next to one another. In most cases, they are found at the 6-o'clock and 12-o'clock positions (inlet/exhaust) along the transverse engine axis.Findings not critical.

Smoothened area Smoothened areas are on the running surface but almost the whole honingpattern is still visible. Smoothened areas appear brighter and more brilliantthan the surrounding running surface.Findings not critical.

Polished area Polished areas are on the running surface and show local removal of the honing pattern. Grooves from honing process are not visible any more.

Discoloration This is caused by oxidation (surface discoloration through oil or fuel) and temperature differences around the liner. It appears rather darker within the honedstructure in contrast to the bright metallic running surface. The honing patternis undisturbed. Discolorations extend in stroke direction and may be interrupted.Findings not critical.

Corrosion fields / spots Corrosion fields / spots result from water (condensed water) with the valves inthe overlap (open) position. They are clearly visible due to the dark color of thehoning groove bottom.This corrosion is not critical unless there are corrosion pittings.

Black lines Black lines are a step towards heat discoloration. They are visible as a cleardiscoloration from TDC to BDC in the running surface and the start of localizeddamage to the honing pattern.Cylinders with a number of black lines around the running surface have limitedservice life and should be replaced.


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Finding ActionDiscolorations (Heat) These are caused by a disturbance in the liner / ring tribosystem. Usually they

run over the whole ring-travel area (TDC/BDC), starting at the first TDC-ringand becoming more visible from the second TDC-ring onwards and less pronounced from TDC-ring 1. The honing pattern is usually no longer visible anddisplays a clearly defined (straight) edge to the undisturbed surface. The damaged surface is usually discolored. The circumferential length varies.Liners with heat discoloration starting in the TDC-ring 1 have to be replaced.

Seizures, Seizuremarks

Irregular circumference lengths and depths. Can be caused either by the piston skirt or the piston crown. Material deposits on the liner (smear), heavy discoloration. Severe, visible scoring.Replace liner.

Evaluation of findings and further measuresThe findings in the start phase of oxidation discoloration and heat discoloration are similar. Thorough investigation and compliance with the above evaluation criteria allows a definite evaluation. To avoid unnecessary disassembly work, it is recommended that another inspection be carried out after further operation of the engine.


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7.4 Crankcase Breather7.4.1 Crankcase breather Cleaning oil pre-separator element

Preconditions Engine is stopped and starting disabled.

WARNING Fuels are combustible.Risk of fire and explosion! Avoid open flames, electrical sparks and ignition sources. Do not smoke.

WARNING Compressed airRisk of injury! Do not direct compressed-air jet at persons. Wear protective goggles / safety mask and ear protectors.

Crankcase breather, cleaning oilpre-separator element

1. Remove cover (5) from housing (4).2. Take off oil pre-separator element (1), gas

ket (3) and O-ring (2).3. Wash oil pre-separator element (1) and

housing (4) in fuel and blow out with compressed air.

4. Moisten oil pre-separator element (1) withengine oil.

5. Position oil pre-separator element (1) withnew gasket (3) and O-ring (2) on housing(4) and install cover (5).

6. Clean further oil pre-separator elements inthe same way.


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7.4.2 Crankcase breather Oil separator replacement, diaphragm check andreplacement


Designation / Use Part No

MTU 12-16V2000 M72 Operating Instructions

Documents

Transcript of MTU 12-16V2000 M72 Operating Instructions